Plywood box construction



April 12, 1955 Filed May 16, 1952 R. A. MULLER PLYWOOD BOX CONSTRUCTION 3 Sheets-Sheet 1 April 12, 1955 R. A. MULLER 2,706,053 4 PLYWOOD BOX CONSTRUCTION Filed May 16, 1952 3 Sheets-Sheet 2 34 e34 38 I 1 lo I l I L 1 a so 0 0 April 12, 1955 A. MULLER PLYWOOD BOX CONSTRUCTION Filed May 16, 1 952 //I/ III/f 3 Sheets-Sheet 3 75,160 a. Way;

PLYWOOD BOX CONSTRUCTION Robert A. Muller, New London, N. H., assignor to Atlas Plywood Corporation, Boston, Mass, a comoration of Massachusetts Application May 16, 1952, Serial No. 288,221

1 Claim. (Cl. 217-43) chandise, there is a need for a cheap, light crating means which will protect the top and sides of the mechandise with the bottom, or possibly bottom and two sides being left open during shipment and handling.

It is an object of the present invention to improve packmg cases of the panel type and to devise especially a knock-down plywood panel type of container which may be very efiiciently and cheaply constructed in separate parts and which will, nevertheless, in a fully assembled form, provide for an exceedingly high degree of strength.

The invention also aims to provide a knock-down type of plywood packing case constructed from relatively few parts, which can be very conveniently built up from a base member into a fully assembled container, with a view especially to forming the base member so that it may be easily placed under heavy mechandise of the type described in order that the sides and top may be thereafter secured to the base without having to change the position of the article.

Still another object of the invention is to devise a combined frame work and supported panel structure wherein one or more of the sides may be of open-work type to secure the greatest possible lightness and accessibility while preserving a necessary degree of rigidity and strength.

These and other objects and novel features will be more fully understood and appreciated from the following description of a preferred embodiment of the invention selected for purposes of illustration and shown in the accompanying drawings, in which Fig. 1 is a perspective exploded View of the component parts of the packing case of the invention, especially illustrating the hinged panel assembly in a substantially fiat position;

Fig. 2 is a perspective view showing the packing case in a fully assembled condition;

Fig. 3 is a view in cross-section taken on the line 3-3 of Fig. 2;

Fig. 4 is another view in cross-section corresponding to Fig. 3 but further showing the hinged panel assembly in a partially raised position;

Fig. 5 is a detail cross-sectional view taken on the line 55 of Fig. 2;

Fig. 6 is a perspective view showing a modified form of end wall member; and

Fig. 7 is a perspective view showing a modified packing case constructed with an end wall structure such as that shown in Fig. 6. y

In the structure shown in Figs. 1 to 5, inclusive, there has been illustrated one preferred embodiment of the invention in which I have provided closed top, end and side portions constructed on an open-work type of base. Attention is particularly directed to Fig. 1 wherein is shown, in separated relationship, the open-work base member generally denoted by the arrow A, together with end walls denoted by the arrow B, of which only one appears, and a folding or hinged panel assembly denoted by the arrow C.

The base member A is constructed as a separate unit and includes a pair of spaced-apart bottom rails 2 and 4 preferably consisting of strips of wood or other desired United States Patent 0 (ill 2,706,063 Patented Apr. 12, 1955 building material. Located transversely across the upper sides of the rails are two cross pieces 6 and 8 which are solidly secured by nails or other fastenings to the rails in recessed relation to the extremities of these members so as to form four corners, as shown in Fig. 1. Secured between two opposite corners of this frame thus formed and resting on the upper surfaces of the rails 2 and 4 is further provided a diagonally extending base member 10 which has its ends preferably lying in abutting relationship to the cross pieces 6 and 8.

Also constructed as separate units are a pair of end walls corresponding to the end wall B shown in Fig. 1. These members comprise top and bottom frame pieces 12 and 14 and two vertical side pieces 16 and 18 which are nailed or otherwise fastened in abutting relation to the top and bottom pieces 12 and 14. Each of the upper corners of the top frame piece 12 is rabbetted, as shown, to form relieved surfaces 20 and 22.

At the inner surfaces of the frame thus provided is solidly secured a panel 24 preferably composed of plywood and cut to size to have its edges occurring flush with the edges of the frame described and including recessed corner surfaces 26 and 28. Each of the end walls B are attached to the base A with their lower edges fitted into the corners comprised by the rails and cross pieces, as described above.

This arrangement is further shown in Fig. 5 in which it will be observed that by providing corners, as noted, the bottom edge of the plywood panel 24 rests on the rails 2 and 4 and is also abutted against the adjacent cross piece 6 so that it becomes locked between the cross piece 6 and the bottom strip 14 and is thus supported on two opposite sides, as shown in Fig. 5. It is found, moreover, that when thus supported a single screw fastening, as 30, will adequately hold the side walls to the base until the remaining portions of the box can be attached and secured in place. In a similar manner the second end wall member is secured to the opposite end'of the base member A.

To complete the packing case I have devised the novel folding panel assembly C, as illustrated in Fig. 1. An important feature of the invention is the fabrication of this panel assembly from a plurality of plywood panels 34, 36 and 38 which constitute two sides and a top for the packing case.

In accordance with the invention I combine with these panels a pair of folding strips or hinge members 40 or 42 preferably consisting of paper, board, or other cheap fibrous material of the type which is sometimes employed for hinging purposes in packing cases. The hinged members may be formed with centrally channeled portions which facilitate hinging.

I have found that these panels may be very advantageously secured or stitched together, making use of a wire stapling machine of the type commonly employed for various stapling purposes. Such a machine may, I find, be utilized in conjunction with a suitable work table for supporting at least two of the panels in a fiat state with the hinge members applied thereover so that a row of wire staples, as 44, may be quickly driven through the hinge 40 and underlying panel 36. Similarly, a row of stitches 46 may be driven through the hinge 40 and panel 34. The hinge 42 is fastened to panels 36 and 38 in the same manner.

Thereafter the panel 36 has fastened at its under side a pair of supporting cleats 50 and 52, better shown in Figs. 1 and 2. These cleat members are chosen of a length such that they extend the full length of the panel structure and have their extremities flush with the exposed surfaces of the end wall B. Also, the width of the cleats is made to conform to the width of the relieved surfaces 20 and 22 in the manner shown in Fig. 2. It should also be observed that the hinge members are attached to the cleats at points such that a portion of each hinge will overlie the sides of the cleats and extend downwardly in planes which intersect the edges of the end walls B.

The hinged panel assembly C in the flat state shown in Fig. 1 is then folded into a U-shaped enclosing body and can readily be attached to the base A and end walls B to assume a position such as that shown in Fig. 2. It will be observed that the side panels 34 and 38 are cut of a width such that when they are attached to the hinge members, with a small overlap, they will overlie the respective end walls with their bottom edges extending dowwnardly to cover the rails 2 and 4 and with the top panel resting or hearing directly on the top edge of the end wall panels 24. It is also pointed out that all three of the panels 34, 36 and 38 are chosen of a length such that they may be flush with the outer edges of the end walls B.

The cleats 50 and 52 are snugly fitted into the corners of the end walls B to provide an excellent braced construction without the cleats actually having to be fastened to the side walls. This is due to the fact that by having the side edges of the panels 24 bearing against the inner surfaces of the panels 34 and 38 and by screwing each of the panels 34, 36 and 38 to the two end walls at top and side edges thereof, the several box parts are very rigidly locked together and do not require additional fastening means.

It will be seen that with the panels in their abutted relationship, as shown, there are obtained braced corners at four points around the box and the base is braced with the single diagonally extending member to prevent racking of the box when subjected to severe shipping stresses. A minimum number of fastening operations are then required, and this is due to the over-all balanced bracing effect obtained by associating the panels in the unique relationship desired. Much saving of time, labor and materials can be realized in this way.

In assembling the packing case with an article of merchandise such as a gas stove or an electric range, it will further be apparent that it is extremely convenient to raise one side of the article and slide the base A in place thereunder. If desired, the article may be directly bolted or otherwise secured to the base. Thereafter the two end walls can be fitted into place against the base cross pieces and screwed into place with suitable wedge pieces or blocking means being inserted, if desired.

The panel assembly C may then be placed over the article and fastened to the base in the manner described without requiring any further handling of the article to be shipped. It is pointed out that the hinged panel may be made use of in various ways. For example, either one of the panels 34 or 38 may be left unfastened to provide access to the packing case, or one of the panels may be unfastened after it has been secured to facilitate access to the packing case at any time. If desired, the panels on two opposite sides, i. e., panels 34 and 38, may be unfastened and raised up to permit access to either or both sides of the packing case.

Still another alternative is to leave one side secured and to unfasten the top panel 36 and one of the remaining panels, with the result that the side and top thus unfastened may be raised up as a single unit to permit access to the packing case from both the top and one side.

In comparison with a conventional wooden crate or box customarily employed for crating heavy articles of the type dealt with here, it will be seen that a very greatly simplified packing case is provided through the use of light, thin plywood panels which can be carried on a frame work of a surprisingly small number of frame pieces owing to the novel brace relationship of the panels with respect to one another.

The bottom or base being open, provides a desirable increase in lightness and saving in box material. These features taken in conjunction with the unique braced relationship of the various panel components, constitutes a very efficient plywood type of packing case construction which, so far as I am aware, has not been devised up to the present time.

If desired, I may also employ the base A as a pallet member for supporting the goods either before or after shipment with the end walls B and panel assembly C removed. It will be apparent that by utilizing the rails 2 and 4 of a suitable thickness of stock, there will be provided a space between these members and underneath the cross pieces 6 and 8 into which may be inserted the fork elements of a lift truck and the merchandise may then be handled in the customary way employed with these devices.

In Figs. 6 and 7 I have illustrated a modification of the invention comprising a box which is similar in nature to the box shown in Figs. 1 to 5, inclusive, with the difference that the end walls have been constructed with a special open-work arrangement.

In this modified construction I may employ a base similar to the base already described and shown in Figs. 1 to 5, inclusive. In conjunction with such a base I provide end wall members, such as the end wall member denoted by the arrow D, and specifically shown in Fig. 6. In this end wall construction I provide top and bottom pieces and 52 with the member 50 being formed with relieved surfaces 54 and 56. Vertical strips 58 and 60 are secured against the outer surfaces of these top and bottom pieces 50 and 52 in the manner shown, being secured by nails or other suitable fastenings. The top surfaces of the pieces 58 and 60 are arranged to lie in the same plane with the relieved surfaces 54 and 56 of the member 50. Diagonal braces 62 and 64 are attached in crosswise overlapping relation, as shown.

In Fig. 7 the end walls D have been further illustrated to support a hinged panel assembly which is generally denoted by the arrow E and which includes panels 66, 68 and 70 secured in hinged relationship by means of hinges 72 and 74 of the character already described and secured by stapling, as has also been explained above. With this hinged panel assembly are provided elongated cleats 76 and 78 which project beyond the panel edges, as shown in Fig. 7, to lie flush with the outer surfaces of members 58 and 60. Screw fastenings 80 may be driven vertically downwardly through the brace in to the underlying support member to conveniently secure these members together. It will be observed that to provide for this manner of securing the cleats to the bottom surfaces of the end wall frame pieces, as described, I have chosen the center panel 68 of a length less than the length of the two adjoining panels 66 and 70. The latter members project beyond their respective hinges 72 and 74 and extend into overlapping relationship with respect to adjacent surfaces of the members 58 and 60, as shown.

By thus combining the panels with the end walls, a very satisfactory bracing efiect for some shipping purposes may be realized and yet there is made available a substantial saving in material, as well as an increase in lightness in the packing case, by having openwork end walls, as well as an open-work base.

From the foregoing description it will be evident that I have provided a novel and highly useful packing case comprising a unique combination of hinged panels and supporting frame members with the panels associated with one another such that a series of abutting edges are made use of at different points throughout the box to secure great strength and rigidity with a minimum weight factor and requiring very few operations to place and secure together the component parts. These features are furthermore designed so that each part of the assembly may be located very advantageously in building up a crate frame-work for heavy merchandise of the classes indicated.

While I have shown two preferred embodiments of the invention, it should be understood that I may resort to changes and modifications in other Ways within the scope of the appended claim.

I claim:

An improved plywood packing case comprising a relatively heavy open-work base member, said base member including a pair of spaced apart bottom rails with cross pieces connecting the upper faces of said rails at points spaced inwardly from their ends, said rails being further braced by a diagonal member arranged between said cross pieces, removable opposed end walls for said case, each of said end walls including a relatively heavy frame and a cover panel, said frame including top and bottom horizontal frame elements and connecting end elements, the top frame elements being recessed at their outer upper corners, the bottom frame element of each of said end walls being adapted to rest upon the outwardly extending ends of the spaced side rails of the base and to abut the outer edges of the cross pieces throughout their entire length, means securing the bottom portion of the end walls to the medial portion of the cross pieces, thereby forming a relatively heavy cradle assembly and a removable sectional panel structure forming the top and front and rear side walls of the case, said panel structure being formed of spaced parallel sheets of plywood connected by hinge members at their adjacent edges, said hinge members each being formed of strips of material substantially overlying the adjacent marginal edges of the panel and having a medial flexible portion at the area between the spaced panels, said hinge members being secured to said paneling throughout its longitudinal marginal edges to provide three rigid panel elements arranged in tandem and hinged at their adjacent edges,

teners' extending therethrough and into the bottom portions of the end frames.

References Cited in the file of this patent UNITED STATES PATENTS 1,931,461 MacKenzie Oct. 17, 1933 1,987,305 Miller Jan. 8, 1935 2,071,962 Babcock Feb. 23, 1937 2,217,210 Bigelow et al. Oct. 8, 1940 2,332,652 MacKenzie Oct. 26, 1943 2,361,937 Gondert Nov. 7, 1944 2,442,651 Johnson June 1, 1948 2,488,692 Talbot Nov. 22, 1949 

